Vehicle interior component

ABSTRACT

A vehicle interior component is disclosed. The component may comprise a composite structure comprising a substrate and light guide and surface/cover with holes/pattern of apertures configured for illumination (by a light source/module) to provide an interface/display (with decorative and/or instrumentation region). The light guide may comprise a resin material formed as the set of projections in the pattern of apertures. The cover may comprise a decorative layer with backing configured to provide a visual/surface effect (e.g. natural material, wood veneer, etc.); the display may present a visual/decorative effect when illuminated at the pattern of apertures/light guide. The interface/display at the surface (by illuminated light guide/pattern of holes) may present indicia for a vehicle system and/or decorative effect. The component may comprise a trim/trim panel, instrument panel/dashboard, door panel/armrest, console, overhead trim/headliner, pillar/structure, seat, etc.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of International/PCT PatentApplication No. PCT/US19/56373 titled “VEHICLE INTERIOR COMPONENT” filedOct. 15, 2019, which claims the benefit of U.S. Provisional PatentApplication No. 62/808,290, titled “VEHICLE INTERIOR COMPONENT” filedFeb. 20, 2019 and U.S. Provisional Patent Application No. 62/748,183titled “VEHICLE INTERIOR COMPONENT” filed Oct. 19, 2018.

The present application claims priority to and incorporates by referencein full the following patent applications: (a) U.S. Provisional PatentApplication No. 62/748,183 titled “VEHICLE INTERIOR COMPONENT” filedOct. 19, 2018; (b) U.S. Provisional Patent Application No. 62/808,290,titled “VEHICLE INTERIOR COMPONENT” filed Feb. 20, 2019, (c)International/PCT Patent Application No. PCT/US19/56373 titled “VEHICLEINTERIOR COMPONENT” filed Oct. 15, 2019; (d) U.S. patent applicationSer. No. 16/777,286 (now U.S. Pat. No. 10,821,889) titled “VEHICLEINTERIOR COMPONENT” filed Jan. 30, 2020.

FIELD

The present invention relates to a vehicle interior component.

BACKGROUND

It is known to provide a vehicle interior component configured forilluminated and non-illuminated states.

It would be advantageous to provide an improved vehicle interiorcomponent with an improved configuration to provide illumination at thesurface or cover.

SUMMARY

The present invention relates to a component for a vehicle interior witha surface intended to be visible to an occupant when the component isinstalled in the vehicle interior configured to provide illuminationfrom a light source comprising a base, a decorative layer coupled to thebase comprising at least one hole and a light guide coupled to thedecorative layer. The light guide may comprise a first portionconfigured to fill the at least one hole in the decorative layer. Thecomponent may comprise a backing coupled to a rear surface of thedecorative layer. The at least one hole may comprise a pattern of holesconfigured to provide indicia identifying at least one vehicle control.The decorative layer may comprise a backer configured to preventillumination to pass from a light source to an outer surface of thedecorative layer. The light guide may be formed within the at least onehole of the decorative layer. The decorative layer may be configured toprovide a visual effect; the light guide may be configured to provide avisual effect; the visual effect of the decorative layer and the visualeffect of the light guide may be configured to provide a compositevisual effect.

The present invention relates to a method of manufacturing a vehicletrim component comprising the steps of providing a decorative layer,providing the decorative layer in a tool, at least one of forming and/orcutting the decorative layer into a shape, forming at least one hole inthe decorative layer, providing the decorative layer in a mold,injecting a resin in the mold to form a light guide in the at least onehole of the decorative layer, providing a base and joining thedecorative layer with the light guide to the base. The light guide maybe configured to allow illumination to pass through the at least onehole of the decorative layer. Forming the at least one hole may compriseperforating the decorative layer with a laser. The method may comprisethe step of applying a backer to an inner surface of the decorativelayer. The step of forming at least one hole in the decorative layer maycomprise forming at least one hole in the backer to allow transmissionof light through the at least one hole in the backer.

The present invention relates to a component for a vehicle interiorcomprising a surface configured to be illuminated by a light source topresent an interface for an occupant of the vehicle interior comprisinga base, a cover layer coupled to the base comprising a pattern ofapertures and a light guide coupled to the cover layer. The light guidemay comprise a set of projections configured to fit in the pattern ofapertures of the cover layer. The light guide may be configured totransmit illumination from the light source to present the interfacethrough the pattern of apertures of the cover layer. The cover layer maycomprise a decorative layer for the surface; the decorative layer maycomprise at least one of (a) a natural material; (b) a wood veneer; (c)a grained material; (d) a sheet material providing a surface effect. Thepattern of apertures may comprise at least one hole configured to atleast one of (a) provide an outlet for light configured to provideillumination; (b) direct light to provide illumination. The pattern ofapertures may be configured to provide a display. The component maycomprise a module configured to provide the light source and at leastone sensor for the interface. The component may comprise a backerconfigured to reinforce the cover layer. The backer may be configured toprevent illumination from the light source to an outer surface of thedecorative layer other than at the pattern of apertures. The light guidemay comprise a resin material formed as the set of projections in thepattern of apertures. The cover layer may comprise a decorative layerconfigured to provide a visual effect; the light guide may be configuredto provide a visual effect; the visual effect of the decorative layerand the visual effect of the light guide may be configured to provide acomposite visual effect.

The present invention relates to a component for a vehicle interior witha surface intended to be visible to an occupant when the component isinstalled in the vehicle interior configured to provide illuminationfrom a light source comprising: a base; a decorative layer coupled tothe base comprising at least one hole; and a light guide coupled to thedecorative layer. The light guide may comprise a first portionconfigured to fill the at least one hole in the decorative layer. Thedecorative layer may comprise a thickness generally between 0.005 inchesand 0.05 inches. The decorative layer may comprise a rear surface; thelight guide may comprise a second portion configured to align with therear surface of the decorative layer and guide light from a light sourceto the first portion of the light guide. The decorative layer maycomprise a natural material. The decorative layer may comprise a woodveneer. The component may further comprise a backing coupled to a rearsurface of the decorative layer. The backing may comprise at least onebacker attached to the rear surface of the decorative layer. The atleast one backer may comprise a sheet material; the at last one hole maycomprise a set of holes through the decorative layer and the sheetmaterial of the at least one backer; the set of holes may be configured(a) to provide an outlet for light configured to provide illuminationand/or (b) to direct light to provide illumination at the surface. Theat least one hole may be configured to at least one of (a) provide anoutlet for light configured to provide illumination; (b) direct light toprovide illumination at the surface. The at least one hole may comprisea pattern of holes configured to provide indicia identifying at leastone vehicle control. The decorative layer may comprise a backerconfigured to prevent illumination to pass from a light source to anouter surface of the decorative layer. The light guide may be formedwithin the at least one hole of the decorative layer. The light guidemay comprise a light-transmissive resin material formed in the at leastone hole of the decorative layer. The decorative layer may be configuredto provide a visual effect; the light guide may be configured to providea visual effect; the visual effect of the decorative layer and thevisual effect of the light guide may be configured to provide acomposite visual effect. The surface may be configured for a first stateproviding the visual effect of the decorative layer and a second stateproviding the composite visual effect of the visual effect of the lightguide and the visual effect of the decorative layer. The at least onehole may comprise a pattern of holes; the base may comprise at least oneof (a) module; (b) a switch; (c) a sensor; (d) a capacitive switch; (e)a capacitive switch sensor aligned with the pattern of holes; thepattern of holes may be configured to illuminate the decorative layer toindicate a position of the switch; the capacitive switch; the capacitiveswitch sensor. The component may comprise at least one of a trim panel;an armrest; a headliner; a dashboard; a console; a center console; adoor panel; a steering wheel; a seat; a pillar; a roof pillar; pillartrim.

The present invention relates to a method of manufacturing a vehicletrim component comprising the steps of: (a) providing a decorativelayer; (b) providing the decorative layer in a tool; (c) at least one offorming; cutting the decorative layer into a shape; (d) forming at leastone hole in the decorative layer; (e) providing the decorative layer ina mold; (f) injecting a resin in the mold to form a light guide in theat least one hole of the decorative layer; (g) providing a base; (h)joining the decorative layer with the light guide to the base. The lightguide may be configured to allow illumination to pass through the atleast one hole of the decorative layer. Forming the at least one holemay comprise perforating the decorative layer with a laser. The methodmay further comprise the step of applying a backer to an inner surfaceof the decorative layer. The backer may comprise a barrier configured toprevent transmission of light. The step of forming at least one hole inthe decorative layer may comprise forming at least one hole in thebacker to allow transmission of light through the at least one hole inthe backer. The backer may comprise at least one layer of backingmaterial. The backing material may comprise a sheet material attached tothe inner surface of the decorative layer.

The present invention relates to a component for a vehicle interiorcomprising a surface configured to be illuminated by a light source topresent an interface for an occupant of the vehicle interior comprising:a base; a cover layer coupled to the base comprising a pattern ofapertures; and a light guide coupled to the cover layer. The light guidemay comprise a set of projections configured to fit in the pattern ofapertures of the cover layer; the light guide may be configured totransmit illumination from the light source to present the interfacethrough the pattern of apertures of the cover layer. The cover layer maycomprise a decorative layer for the surface; the decorative layer maycomprise at least one of (a) a natural material; (b) a wood veneer; (c)a grained material; (d) a sheet material providing a surface effect. Thepattern of apertures may comprise at least one hole configured to atleast one of (a) provide an outlet for light configured to provideillumination; (b) direct light to provide illumination. The pattern ofapertures may be configured to provide a display. The display maycomprise at least one of a decorative region and an instrumentationregion. The instrumentation region may comprise indicia identifying atleast one vehicle control. The component may further comprise a moduleconfigured to provide the light source and at least one sensor for theinterface. The component may further comprise a backer configured toreinforce the cover layer. The backer may comprise at least one backinglayer. The backer may comprise the pattern of apertures so thatillumination from the light source passes through the backer to thesurface to provide the interface. The backer may be configured toprevent illumination from the light source to an outer surface of thedecorative layer other than at the pattern of apertures. The light guidemay comprise a light-transmissive resin material. The light guide maycomprise a resin material formed as the set of projections in thepattern of apertures. The cover layer may comprise a decorative layerconfigured to provide a visual effect; the light guide may be configuredto provide a visual effect; the visual effect of the decorative layerand the visual effect of the light guide may be configured to provide acomposite visual effect. The interface may comprise a first stateproviding the visual effect of the decorative layer and a second stateproviding the composite visual effect of the visual effect of the lightguide and the visual effect of the decorative layer. The first state maycomprise an unilluminated state and the second state may comprise anilluminated state.

The present invention relates to a vehicle interior component comprisinga composite structure comprising a surface/cover and a substrate andconfigured to be illuminated in a decorative region by a light sourceand in an instrumentation region by a module.

The present invention relates to a component for a vehicle interior witha surface intended to be visible to an occupant when the component isinstalled in the vehicle interior configured to provide illuminationfrom a light source comprising a base, a decorative layer coupled to thebase comprising at least one hole and a light guide coupled to thedecorative layer. The light guide may comprise a first portionconfigured to fill the at least one hole in the decorative layer. Thedecorative layer may comprise a thickness generally between 0.005 inchesand 0.05 inches. The decorative layer may comprise a rear surface; thelight guide may comprise a second portion configured to align with therear surface of the decorative layer and guide light from a light sourceto the first portion of the light guide. The decorative layer maycomprise a natural material. The decorative layer may comprise a woodveneer. The at least one hole may be configured to at least one of (a)provide an outlet for light configured to provide illumination; (b)direct light to provide illumination. The at least one hole may comprisea pattern of holes configured to provide indicia identifying orassociated with at least one vehicle system (e.g. instrumentation,control, etc.). The base may comprise at least one of (a) a switch (b) asensor (c) a capacitive switch (d) a capacitive switch sensor alignedwith the pattern of holes; the pattern of holes may be configured toilluminate the decorative layer to indicate a position of the switch,the capacitive switch, the capacitive switch sensor. The decorativelayer may comprise a backing/backer configured to prevent illuminationto pass from a light source to an outer surface of the decorative layer.The light guide may be formed within the at least one hole of thedecorative layer. The decorative layer may be configured to provide avisual effect; the light guide may be configured to provide a visualeffect; the visual effect of the decorative layer and the visual effectof the cover may be configured to provide a composite visual effect. Thecomponent may be configured for a first state providing the visualeffect of the decorative layer and a second state providing thecomposite visual effect of the visual effect of the light guide and thevisual effect of the decorative layer. The component may comprise atleast one of a trim panel; an armrest; a headliner; a dashboard; aconsole; a center console; a door panel; a steering wheel; a seat; apillar, a roof pillar, pillar trim.

The present invention also relates to a method of manufacturing avehicle trim component comprising the steps of providing a decorativelayer; disposing the decorative layer in a tool; at least one offorming; cutting the decorative layer into a shape; forming at least onehole in the decorative layer; disposing the decorative layer in a mold;injecting a resin in the mold to form a light guide in the at least onehole of the decorative layer; providing a base; joining the decorativelayer with the light guide to the base. The light guide may beconfigured to allow illumination to pass through the at least one holeof the decorative layer. Forming the at least one hole may compriseperforating the decorative layer with a laser. The method may comprisethe step of applying a backing/backer to an inner surface of thedecorative layer. The backing/backer may comprise a barrier configuredto prevent transmission of light. Forming at least one hole in thedecorative layer may comprise forming at least one hole in thebacking/backer to allow transmission of light through the at least onehole in the backing/backer.

The present invention relates to a component for a vehicle interiorconfigured to be illuminated by a light source to present an interfacefor an occupant of the vehicle interior. The component may comprise abase, a cover layer coupled to the base comprising a pattern ofapertures and a light guide coupled to the cover layer. The light guidemay comprise a set of projections configured to fit in the pattern ofapertures of the cover layer. The light guide may be configured totransmit illumination from the light source to present the interfacethrough the pattern of apertures of the cover layer.

FIGURES

FIG. 1A is a schematic perspective view of a vehicle according to anexemplary embodiment.

FIG. 1B is a schematic perspective cut-away view of a vehicle showing aninterior according to an exemplary embodiment.

FIG. 2A is a schematic rear cut-away view of a vehicle showing aninterior according to an exemplary embodiment.

FIG. 2B is a schematic diagram of a vehicle interior componentcomprising a display according to an exemplary embodiment.

FIG. 2C is a schematic cut-away plan view of a vehicle interiorcomponent comprising a display according to an exemplary embodiment.

FIGS. 3A and 3B are schematic perspective views of a vehicle interiorcomponent according to an exemplary embodiment.

FIGS. 3C and 3D are schematic perspective views of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 4A is a schematic perspective view of a vehicle interior componentshown as an instrument panel according to an exemplary embodiment.

FIG. 4B is a schematic partial perspective view of a vehicle interiorcomponent shown as an instrument panel according to an exemplaryembodiment.

FIG. 4C is a schematic diagram of a vehicle interior componentcomprising a display according to an exemplary embodiment.

FIG. 5A is a schematic perspective view of a vehicle interior componentshown as a door panel according to an exemplary embodiment.

FIG. 5B is a schematic perspective cut-away view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 5C is a schematic exploded view of a vehicle interior componentaccording to an exemplary embodiment.

FIG. 5D is a schematic exploded view of a decorative panel of a vehicleinterior component according to an exemplary embodiment.

FIG. 6 is a schematic plan view of a vehicle interior componentaccording to an exemplary embodiment.

FIG. 6A is a schematic plan view of a vehicle interior componentaccording to an exemplary embodiment.

FIG. 6B is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 6C is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 6D is a schematic plan view of a vehicle interior componentaccording to an exemplary embodiment.

FIG. 7 is a schematic exploded view of a vehicle interior componentaccording to an exemplary embodiment.

FIG. 8A is a schematic cut-away section view of a conventional vehicleinterior component according to an exemplary embodiment.

FIG. 8B is a schematic cut-away plan view of a conventional vehicleinterior component according to an exemplary embodiment.

FIG. 9A is a schematic cut-away section view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 9B is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIGS. 9C to 9E are schematic section views of a process to produce avehicle interior component according to an exemplary embodiment.

FIG. 9F is a schematic cut-away section view of a decorative panel of avehicle interior component according to an exemplary embodiment.

FIG. 9G is a schematic cut-away exploded section view of a decorativepanel of a vehicle interior component according to an exemplaryembodiment.

FIG. 10 is a schematic cut-away section view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 10A is a schematic perspective cut-away view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 10B is a schematic perspective cut-away view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 10C is a schematic perspective cut-away view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 10D is a schematic perspective cut-away view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 10E is a schematic perspective cut-away view of a vehicle interiorcomponent configured to present a display/image according to anexemplary embodiment.

FIG. 10F is a schematic perspective cut-away view of a vehicle interiorcomponent configured to present a display/image according to anexemplary embodiment.

FIG. 11A is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 11B is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 11C is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 12A is a schematic cut-away perspective view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 12B is a schematic cut-away perspective view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 12C is a schematic cut-away perspective view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 13A is a schematic cut-away plan view of a vehicle interiorcomponent according to an exemplary embodiment.

FIG. 13B is a schematic cut-away exploded perspective view of a vehicleinterior component according to an exemplary embodiment.

FIGS. 14A and 14B are schematic cut-away section views of a decorativepanel of a vehicle interior component according to an exemplaryembodiment.

FIGS. 15A and 15B are schematic cut-away section views of a decorativepanel of a vehicle interior component according to an exemplaryembodiment.

FIG. 16 is a schematic cut-away section view of a process to produce acover for a vehicle interior component according to an exemplaryembodiment.

FIG. 17 is a schematic cut-away section view of a process to produce acover for a vehicle interior component according to an exemplaryembodiment.

FIGS. 18A to 18C are schematic cut-away section view of a process toproduce a vehicle interior component according to an exemplaryembodiment.

FIGS. 19A to 19C are schematic cut-away section view of a process toproduce a vehicle interior component according to an exemplaryembodiment.

FIG. 20A is a schematic cut-away perspective view of a light guide for avehicle interior component according to an exemplary embodiment.

FIG. 20B is a schematic cut-away perspective view of a light guide for avehicle interior component according to an exemplary embodiment.

FIG. 20C is a schematic cut-away perspective view of a light guide for avehicle interior component according to an exemplary embodiment.

FIG. 20D is a schematic cut-away perspective view of a light guide for avehicle interior component according to an exemplary embodiment.

FIG. 21A is a schematic cut-away section view of a cover for a vehicleinterior component according to an exemplary embodiment.

FIG. 21B is a schematic cut-away section view of a cover for a vehicleinterior component according to an exemplary embodiment.

FIG. 21C is a schematic cut-away perspective view of a cover for avehicle interior component according to an exemplary embodiment.

FIGS. 22A to 22C are schematic flow diagrams of methods to produce avehicle interior component according to an exemplary embodiment.

FIG. 23 is a schematic flow diagram of a method to produce a vehicleinterior component according to an exemplary embodiment.

DESCRIPTION

Referring to FIGS. 1A and 1B a vehicle V providing an interior I isshown according to an exemplary embodiment. The interior I of thevehicle V may comprise interior components/systems including panels(e.g. instrument panel, door panels, etc.) and consoles (e.g. floorconsole, overhead console, etc.) and other trim components. See alsoFIGS. 1B, 2A, 4A and 5A.

According to an exemplary embodiment as shown schematically in FIGS. 1Band 2A, the interior of the vehicle may comprise components C configuredto provide a user interface/system such as through a display Dconfigured to display an image IM As shown schematically in FIGS. 2A and3A-3C, the user interface system/component C may comprise asurface/panel providing a surface effect SE (e.g. texture, color,contour, visual effect, image display, etc.); as shown schematically inFIGS. 3A and 3B, the component C may comprise a surface effect SE suchas wood trim/grain (e.g. wood veneer, finish, etc.); as shownschematically in FIGS. 3C and 3D, the component C may comprise a surfaceeffect SE such as formed/molded contour (e.g. with visual/texture effectsuch as plastic, metallic, natural materials, etc.).

As indicated schematically according to an exemplary embodiment in FIGS.3A-3D, the component C may be configured to be illuminated (e.g. from alight source). See also FIG. 7 (e.g. light source L withlighting/control module M). As indicated schematically in FIGS. 3A and3C, until illumination is provided the component C may be configured topresent the general appearance of the cover/surface (e.g. woodveneer/surface as in FIG. 3A or contour/surface as in FIG. 3B). Asindicated schematically in FIGS. 3B and 3D, when illumination isprovided (e.g. from light source L through the substrate/surface to thecover/surface) the component C may be configured to present through thesurface effect an intended visible effect shown as an image IM (e.g.illuminated image visible through/at/on the surface). As indicatedschematically, the image IM is presented as an illuminated form at thesurface (e.g. user interface) of the component C. See FIGS. 3B and 3D(showing image IM in the form of an icon set of a type as may indicate alocked or unlocked status of a vehicle door or other system). As shownschematically in FIGS. 3B, 3D, 14A-14B and 15A-15B, the image SH/IMpresenting the icon set to indicated an locked/unlocked state maycomprise a set of apertures/perforations shown as holes H through thecover/surface (e.g. holes through the cover and any intermediate layersuch as a backing/layer of a material that is not light-transmissive) totransmit light from the light source (e.g. to present a back-lit imagefrom a form presented at the light source and/or by arrangement/patternof the holes). See also FIGS. 11A-11C, 12A-12C and 13A-13B.

As shown schematically in FIGS. 4A-4B and 5A-5D, the component P may beconfigured for implementation in a decorative trim part/component C/Pshown as a floor console FC to present a display D for an instrumentpanel IP or as a trim component P/200 for a door panel P/1000; accordingto an exemplary embodiment the trim part/component may be configured asany of a variety of other interior trim components for a vehicle(including a decorative trim component/product). As shown schematicallyin FIGS. 4B and 5B, the trim component may provide a surface on whichmay be presented an ornamental design/visible effect shown as image IM(when illuminated by a light source/back-lit display). See also FIGS.6B-6D. As indicated in FIGS. 4A and 5A, unless/until illuminated by thelight source (e.g. until back-lit from the light source) the trimcomponent may present the surface effect (without an image). See alsoFIGS. 3A, 3C, 4A, 5A and 6A.

Referring to FIGS. 2B-2C, 4C, 6, 6A-6D and 7, the component/product Pmay comprise a user interface comprising a decorative region DR where anornamental design/visible effect such as a decorative image may bepresented (e.g. a decorative image made visible on the surface as inFIG. 6B) and an instrumentation region IR where a visible effect such ascontent in the form of information/signals may be presented (e.g.content made visible on the surface as in FIG. 6C); as indicatedschematically, when the component/user interface is illuminated theimage may be presented/projected through the surface effect SE of thecover of the component shown as a wood trim/grain effect W (which effectis visible when the image is not presented). Compare FIGS. 6A(off/unilluminated) and 6D (illuminated).

As indicated schematically in FIGS. 6A-6D, trim component product P isprovided with a surface effect shown as wood trim/grain W that may beconfigured to provide an intended ornamental design/visible effect in adecorative region DR when provided with back-lit illumination (e.g. frommodule L in FIG. 7) and an information/instrumentation display in aninstrumentation region IR when provided with back-lit illumination (e.g.from module M in FIG. 7). As shown schematically according to anexemplary embodiment in FIG. 6A, the product P presents the surfaceeffect of the wood trim/grain W (e.g. cover layer) until illumination isprovided (e.g. until back lit from the light source L). As shownschematically in FIGS. 6B and 6D, when the decorative region DR isilluminated (e.g. back lit from light source L) the ornamental/visualeffect shown as a decorative image of a specified industrial design(e.g. an illuminated arrangement of circle-shaped forms) is presented onthe wood trim/grain surface W of the product P; as shown schematicallyin FIGS. 6C and 6D, when the instrumentation region IR is illuminated(e.g. back lit from light source M) the information/data display ispresented on the wood trim/grain surface W of the product P. See alsoFIG. 4B.

As shown schematically according to an exemplary embodiment in FIG. 7,the component/product P may comprise a composite structure comprising acover/top layer P (e.g. providing the surface/surface effect) and abacking layer (shown as backing layers BL) and a substrate S (which maycomprise or be attached to a carrier/structure); as shown schematicallyin FIG. 7, a light source L (e.g. an LED array/substrate aligned withthe decorative region DR) and an instrumentation module M (e.g. a modulecomprising a light source aligned with the instrumentation region IR maybe provided to illuminate and/or actuate the user interface.

Referring to FIGS. 9A and 9B, the component/product P/200 may comprise acomposite structure with a light array/module L/600 (comprising a lightsource such as an LED/array) and a substrate/light guide 230 (comprisinga light-transmitting and/or generally transparent material 230 b)supporting the surface/cover T/210 with backing shown as layers 220a/220 b (e.g. backing layer BL of a material such as paper, film, foil,fiber, sheet material, etc.); as indicated schematically, holes areprovided in the surface/cover with backing for transmission of lightfrom the light source L/600 through the substrate/fill 230 a/230 b. Seealso FIG. 9B (showing surface with substrate S/fill 230 a of alight-transmissive material for transmission of light from light sourceas a light guide).

As shown schematically according to an exemplary embodiment in FIGS.9C-9F, the component may be formed by injection molding (e.g. in a toolcomprising mold sections MT and MB) of the material for substrate S/fill230 (e.g. transparent and/or light-transmitting material) onto thecover/backing into which holes have been provided; the substratematerial 230 forms projections 230 a (e.g. shown as posts of thelight-transmissive transparent/translucent substrate material) into theholes; the projections/fill posts are configured to function as lightguides. See also FIGS. 9F and 9G.

As shown schematically in FIGS. 3A-3D, 10 and 10A-10F, according to anexemplary embodiment, the component product P may comprise a cover shownas wood veneer/surface W (wood trim/grain) with a backing shown as layerarrangement BL over a substrate S; the surface of the product P (e.g.component C with display D) may be configured to be illuminated (e.g.from light source L on underside below substrate) through the wood trimcover W and backing arrangement BL through an pattern/arrangement of aseries of apertures/holes H; the apertures/holes are filled withposts/fill material F (e.g. light-transmissive transparent/translucentresin R molded with substrate S under the cover/backing). See also FIGS.9A-9G, 13A-13B, 18B-18C, 19B-19C, 20A_20D and 21B-21C. As shownschematically in FIGS. 3B, 3D, 4A, 5A, 6A-6D, pattern/arrangement forthe apertures/holes H and corresponding posts/fill material F maycomprise a shape/image SH/IM such as a geometric form, a symbol, etc. topresent the ornamental/visual effect or information/display (e.g.illuminated form when illuminated from the light source L/M) on the woodtrim/grain surface W of the product P. See also FIGS. 2B-2C, 4C, 9A-9Gand 10A-10F.

As indicated schematically in FIGS. 6A, 6D, 7 and 10A-10D, untilillumination is provided (e.g. from light source L/M through thesubstrate/fill material F for holes H) the back-lit decorative trimcomponent product P may be configured to present the general appearanceof the wood veneer/surface W in decorative region DR and instrumentationregion IR; when illumination is provided (e.g. from light source Lthrough the substrate/fill material F for holes H) the back-litdecorative trim component product P/Pa may be configured to present anintended ornamental design/visible effect in decorative region DR and/orinformation display at instrumentation region IR through the woodveneer/surface W.

As shown schematically in FIGS. 11A-11C, 12A-12C and 13A, thecover/layer T may comprise holes H that are presented in a patternintended to be uniform but in variety of sizes forms/shapes (e.g.circular, elongated, hexagonal, irregular, etc.). See also FIGS. 16 and17 (showing laser tool/system LT providing beam LB and cutting tool CTto form holes in cover/backing T). As shown schematically in FIG. 13B,the fill/posts F formed of the substrate material (e.g. formed materialconfigured to be light-transmissive, translucent, transparent, etc.)will take the form of the hole/aperture in the cover/backing; uniformlyshaped holes will be formed with uniformly shaped/formed fill/posts (seeFIGS. 18A-18C and 20A-20B); irregularly shaped holes will be filled withirregularly shaped/formed posts (see FIGS. 19A-19C, 20C-20D and21A-21C). See also FIGS. 9A-9G.

As shown schematically according to an exemplary embodiment, the woodveneer cover/layer (front) and backing layer (e.g. paper/sheet behindwood veneer cover/layer) (rear) may comprise holes/apertures (e.g.perforations formed by laser tool). As shown schematically, thesurfaces/consistency of the wood veneer cover/layer and the backinglayer comprise an irregular form (e.g. with notable variations insurface, evenness, etc.); the holes/apertures formed through thecover/backing comprise an irregular form (e.g. with variations in size,evenness, etc.). See FIGS. 13A-13B, 19A-19C, 20C-20D and 21A-21C. Asshown schematically in FIGS. 14A-14B and 15A-15B, the hole arrangementwith holes H of intended/effective diameter DM for the image SH/IM onthe surface of the composite structure/component may be configured in agrid pattern alignment with spacing X1/Y1 (on hole borders) or in anoffset/nested pattern with spacing X2/Y2 (on hole centers). CompareFIGS. 11A/11C and 11B/13A (showing irregular form/pattern for holearrangement). As indicated schematically in FIGS. 13A-13B, the holepatterns in a material such as a fiber sheet/veneer may compriseirregularities. See also FIGS. 19A-19C, 20C-20D and 21A-21C.

As shown schematically in according to an exemplary embodiment in FIG.15, a configuration for forming holes/apertures (e.g. perforations) bylaser tool/system LT providing laser beam LB is shown;settings/configuration for the laser tool may comprise thefrequency/density of the laser-formed/applied holes and the width of theline between the laser-formed/applied holes; as indicated schematically,the laser-formed/applied holes in the cover/backing of the component maycomprise variations in form/shape (e.g. generally circular, hexagonal,irregular due to material variations, etc.) according to an exemplaryembodiment (e.g. for forming holes/apertures (e.g. dot frequency andline width for image for instrumentation region). See also FIG. 16(showing operation of laser tool LT with beam LB forming hole/aperturein layer T). Compare FIG. 17 (showing cutting tool CT forming holes inlayer T).

EXEMPLARY EMBODIMENTS—A

As indicated schematically in FIGS. 1B, 2A-2C, 4A and 5A, the componentC may comprise a panel P configured to present a display D (e.g. panelC/P and/or display C/D configured to be operated, illuminated, back-lit,etc.) in the vehicle interior (e.g. such as for a console shown as floorcounsel FC, panel shown as instrument panel IP and/or door panel P/1000,etc.); the display D is configured in operation (e.g. as selectivelyilluminated) to present an image IM for a vehicle occupant (e.g. on orfor a user interface, display panel, control/operator, instrumentationand/or for decorative effect, etc.); the display D may be configured topresent an image IM at a decorative region DR and/or an instrumentationregion IR. See also FIGS. 3A-3D and 4A-4C, 6 and 6A-6D. According to anexemplary embodiment as indicated schematically in FIG. 5B, the image IMpresented at the display D may be configured for a userinterface/control (shown as a door lock and/or window lock); asindicated schematically in FIGS. 6A-6D, the image IM may comprise adecorative effect presented (e.g. by illumination) in a decorativeregion DR of the display D and/or instrumentation/messaging presented(e.g. by illumination, back-lighting, etc.) in an instrumentation regionIR of the display D. According to an exemplary embodiment as indicatedschematically in FIGS. 2A-2B, the component (e.g. shown as display C/Dand panel C/P with display D) may comprise a display configured toprovide a region for illumination configured to present instrumentationand/or decorative effect (e.g. by selective illumination from a modulesuch as comprising an array of light emitting diodes/LED). See e.g.FIGS. 9A and 10A.

As indicated schematically according to an exemplary embodiment in FIGS.16, 17 and 23, the formation of holes/apertures (e.g. perforations bylaser tool or other apparatus/mechanical method) for the component (e.g.back-lit decorative trim component) for a vehicle interior may comprisea variety of patterns/arrangements (e.g. configured to present imageSH/IM for the display on the surface of the component when illuminatedby light source L and/or module M). See e.g. FIGS. 3A-3D, 6A-6D,10A-10F, 11A-11C, 12A-12C, 13A-13B, 14A-14B and 15A-15B. As indicatedschematically according to an exemplary embodiment, the wood veneercover/layer (front) and backing layer (behind wood veneer cover/layer)(rear) with holes/apertures (e.g. perforations formed by laser tool)provide the visual effect/surface effect for the component (e.g.back-lit trim component configured to be illuminated with light sourceL/M/LED) for a vehicle interior. See e.g. FIGS. 3A-3D, 6A-6D, 7, 9A and10E-10F.

As indicated schematically according to an exemplary embodiment, thecomponent providing the display/panel (e.g. configured to present imageIM when actuated/illuminated) may comprise cover layer of a materialconfigured to provide a visual effect at the surface (e.g. shown as awood grain surface effect W/SE). See e.g. FIGS. 3A-3D, 6A-6D, and10A-10F. According to an exemplary embodiment as indicatedschematically, a backing arrangement (e.g. layer or layers withadhesive/coating attachable by bonding, hot press, heat activation,lamination, etc.) may be provided for the cover layer (e.g. attachedbehind the cover of veneer, wood veneer, wood grain, grain material,surface effect layer, etc.) to provide reinforcement (including atholes/apertures), to enhance strength, to protect from damage, tofacilitate handling, to provide environmental resilience (e.g. to water,flame, etc.), for shielding and/or flexibility, etc. See e.g. FIGS. 5D,7, 9A-9G, 10, 10A-10F, 18A-18C, 19A-19C, 21A-21C, 22A-22C and 23.According to an exemplary embodiment the backing layer may comprise abacking material such as commercially available under the name DRIBOND(e.g. #160 TSB thermo-set backer) from Lenderink Technologies ofBelmont, Mich. (USA). According to an exemplary embodiment the backinglayer may comprise a veneer backing material providing a carrier/coatingsuch as commercially available (e.g. under the name PWG Veneer BackingVC300+) from PWG VeneerBackings GmbH of Walkertshofen, Germany.

As indicated schematically according to an exemplary embodiment, acomponent for a vehicle interior with a surface intended to be visibleto an occupant when the component is installed in the vehicle interiorconfigured to provide illumination from a light source may comprise: abase; a decorative layer coupled to the base comprising at least onehole; and a light guide coupled to the decorative layer. The light guidemay comprise a first portion configured to fill the at least one hole inthe decorative layer. The decorative layer may comprise a thicknessgenerally between 0.005 inches and 0.05 inches. The decorative layer maycomprise a rear surface; the light guide may comprise a second portionconfigured to align with the rear surface of the decorative layer andguide light from a light source to the first portion of the light guide.The decorative layer may comprise a natural material. The decorativelayer may comprise a wood veneer. The component may further comprise abacking coupled to a rear surface of the decorative layer. The backingmay comprise at least one backer attached to the rear surface of thedecorative layer. The at least one backer may comprise a sheet material;the at last one hole may comprise a set of holes through the decorativelayer and the sheet material of the at least one backer; the set ofholes may be configured (a) to provide an outlet for light configured toprovide illumination and/or (b) to direct light to provide illuminationat the surface. The at least one hole may be configured to at least oneof (a) provide an outlet for light configured to provide illumination;(b) direct light to provide illumination at the surface. The at leastone hole may comprise a pattern of holes configured to provide indiciaidentifying at least one vehicle control. The decorative layer maycomprise a backer configured to prevent illumination to pass from alight source to an outer surface of the decorative layer. The lightguide may be formed within the at least one hole of the decorativelayer. The light guide may comprise a light-transmissive resin materialformed in the at least one hole of the decorative layer. The decorativelayer may be configured to provide a visual effect; the light guide maybe configured to provide a visual effect; the visual effect of thedecorative layer and the visual effect of the light guide may beconfigured to provide a composite visual effect. The surface may beconfigured for a first state providing the visual effect of thedecorative layer and a second state providing the composite visualeffect of the visual effect of the light guide and the visual effect ofthe decorative layer. The at least one hole may comprise a pattern ofholes; the base may comprise at least one of (a) module; (b) a switch;(c) a sensor; (d) a capacitive switch; (e) a capacitive switch sensoraligned with the pattern of holes; the pattern of holes may beconfigured to illuminate the decorative layer to indicate a position ofthe switch; the capacitive switch; the capacitive switch sensor. Thecomponent may comprise at least one of a trim panel; an armrest; aheadliner; a dashboard; a console; a center console; a door panel; asteering wheel; a seat; a pillar; a roof pillar; pillar trim.

As indicated schematically according to an exemplary embodiment, amethod of manufacturing a vehicle trim component may comprise the stepsof: (a) providing a decorative layer; (b) providing the decorative layerin a tool; (c) at least one of forming; cutting the decorative layerinto a shape; (d) forming at least one hole in the decorative layer; (e)providing the decorative layer in a mold; (f) injecting a resin in themold to form a light guide in the at least one hole of the decorativelayer; (g) providing a base; (h) joining the decorative layer with thelight guide to the base. The light guide may be configured to allowillumination to pass through the at least one hole of the decorativelayer. Forming the at least one hole may comprise perforating thedecorative layer with a laser. The method may further comprise the stepof applying a backer to an inner surface of the decorative layer. Thebacker may comprise a barrier configured to prevent transmission oflight. The step of forming at least one hole in the decorative layer maycomprise forming at least one hole in the backer to allow transmissionof light through the at least one hole in the backer. The backer maycomprise at least one layer of backing material. The backing materialmay comprise a sheet material attached to the inner surface of thedecorative layer.

As indicated schematically according to an exemplary embodiment, acomponent for a vehicle interior comprising a surface configured to beilluminated by a light source to present an interface for an occupant ofthe vehicle interior may comprise: a base; a cover layer coupled to thebase comprising a pattern of apertures; and a light guide coupled to thecover layer. The light guide may comprise a set of projectionsconfigured to fit in the pattern of apertures of the cover layer; thelight guide may be configured to transmit illumination from the lightsource to present the interface through the pattern of apertures of thecover layer. The cover layer may comprise a decorative layer for thesurface; the decorative layer may comprise at least one of (a) a naturalmaterial; (b) a wood veneer; (c) a grained material; (d) a sheetmaterial providing a surface effect. The pattern of apertures maycomprise at least one hole configured to at least one of (a) provide anoutlet for light configured to provide illumination; (b) direct light toprovide illumination. The pattern of apertures may be configured toprovide a display. The display may comprise at least one of a decorativeregion and an instrumentation region. The instrumentation region maycomprise indicia identifying at least one vehicle control. The componentmay further comprise a module configured to provide the light source andat least one sensor for the interface. The component may furthercomprise a backer configured to reinforce the cover layer. The backermay comprise at least one backing layer. The backer may comprise thepattern of apertures so that illumination from the light source passesthrough the backer to the surface to provide the interface. The backermay be configured to prevent illumination from the light source to anouter surface of the decorative layer other than at the pattern ofapertures. The light guide may comprise a light-transmissive resinmaterial. The light guide may comprise a resin material formed as theset of projections in the pattern of apertures. The cover layer maycomprise a decorative layer configured to provide a visual effect; thelight guide may be configured to provide a visual effect; the visualeffect of the decorative layer and the visual effect of the light guidemay be configured to provide a composite visual effect. The interfacemay comprise a first state providing the visual effect of the decorativelayer and a second state providing the composite visual effect of thevisual effect of the light guide and the visual effect of the decorativelayer. The first state may comprise an unilluminated state and thesecond state may comprise an illuminated state.

As indicated schematically, the component/display may be provided in avariety of shapes and forms and/or with a variety ofconfigurations/materials and/or with a variety of patterns forholes/apertures and/or with a variety of surface effects/coverarrangements and/or operated by a variety of types of modules/controlsystems for illumination/back-lighting to serve a variety of functionswithin the vehicle interior (e.g. decorative/ornamental,functional/visual, integrated, instrumentation/control, etc.). See e.g.FIGS. 1B, 2A-2C, 3A-3D, 4A-4C, 5A-5B, 6, 6A-6D, 9A, 10A-10F, 11A-11C,12A-12C, 13A-13B, 14A-14B and 15A-15B.

EXEMPLARY EMBODIMENTS—B

According to an exemplary embodiment as shown schematically in FIGS. 1A,1B and 2A, a vehicle V may include a vehicle interior I. The vehicleinterior may provide components C such as panels, consoles,compartments, etc. Components C may provide a display D (e.g. displaypanel, illumination, data display, display screen, etc.) to presentinformation, alerts, entertainment, data, etc. to a vehicle occupant(e.g. data/information as may be available from various sources such asimage IM as shown in FIGS. 2A, 3A and 3B). The vehicle interior may beprovided with a variety of display configurations in a variety ofpositions and locations to serve a variety of purposes. See e.g. FIGS.1B and 2A.

According to an exemplary embodiment, the component may comprise a trimcomponent, panel, console, etc. provided within the vehicle interior(e.g. instrument panel, door, seat area, cockpit, center area, overhead,etc.). See e.g. FIGS. 1B and 2A.

As indicated schematically according to an exemplary embodiment, thedisplay D of the component may present an image IM and/or information(e.g. data/information, instrumentation, indicators, controls,entertainment, communications, etc.). See e.g. FIGS. 2A and 3B.According to an exemplary embodiment, the image may comprise a set ofholes H. According to an exemplary embodiment, the component C and/ordisplay D (if provided on the component) may provide a contouredform/shape designed/intended to integrate with the interiordesign/aesthetic of the vehicle V. According to an exemplary embodiment,the component C may be provided with a visual effect and formed (e.g.shaped/contoured).

According to an exemplary embodiment as shown schematically in FIGS. 5Ato 5D, 9A, 9F, 9G, 14A and 14B, a component for a vehicle interior 1000shown as a door panel may comprise a surface intended to be visible toan occupant when component 1000 is installed in the vehicle interior. Asshown schematically in FIG. 5B, component 1000 may be configured toprovide illumination shown as an image IM from a light source. Component1000 may comprise a base 100, a decorative layer 210 coupled to base 100comprising at least one hole H and a light guide 230 coupled todecorative layer 210. Light guide 230 may comprise a first portion 230 aconfigured to fill the at least one hole H in decorative layer 210.Decorative layer 210 may comprise a thickness generally between 0.005inches and 0.05 inches (and may be provided with backing layer BL of athickness of 0.01 inch or in a range of between 0.005 and 0.05, e.g. ofone or multiple layers). Decorative layer 210 may comprise a rearsurface; light guide 230 may comprise a second portion 230 b configuredto align with the rear surface of decorative layer 210 and guide lightfrom a light source to first portion 230 a of light guide 230.Decorative layer 210 may comprise a natural material. Decorative layer210 may comprise a wood veneer. The at least one hole H may beconfigured to at least one of (a) provide an outlet for light configuredto provide illumination; (b) direct light to provide illumination. Theat least one hole H may comprise a pattern of holes configured toprovide indicia identifying or associated with at least one vehiclesystem (e.g. instrumentation, control, etc.). Base 100 may comprise atleast one of (a) a switch (b) a sensor (c) a capacitive switch (d) acapacitive switch sensor aligned with the pattern of holes; the patternof holes may be configured to illuminate decorative layer 210 toindicate a position of the switch, the capacitive switch, the capacitiveswitch sensor. Decorative layer 210 may comprise a substrate shown as abacking (or backer) 220 configured to prevent illumination to pass froma light source to an outer surface of decorative layer 210. Light guide230 may be formed within the at least one hole H of decorative layer210. Decorative layer 210 may be configured to provide a visual effect;light guide 230 may be configured to provide a visual effect; the visualeffect of decorative layer 210 and the visual effect of light guide 230may be configured to provide a composite visual effect. Component 1000may be configured for a first state providing the visual effect ofdecorative layer 210 and a second state providing the composite visualeffect of the visual effect of light guide 230 and the visual effect ofdecorative layer 210. Component 1000 may comprise at least one of a trimpanel; an armrest; a headliner; a dashboard; a console; a centerconsole; a door panel; a steering wheel; a seat; a pillar, a roofpillar, pillar trim. As shown schematically in FIGS. 9A, 9F and 9G,component 1000 may comprise a base layer or circuit board L/600comprising a light source shown as a light emitting diode LED. As shownschematically in FIGS. 9A, 9F and 9G, backing (e.g. barrier, backinglayer, backing layers, backer, etc.) 220 may comprise a first backer 220a and a second backer 220 b.

As indicated schematically according to an exemplary embodiment in FIGS.5A-5D, 9A, 9F, 9G, 4A and 4B, the component 1000 may generally beconfigured to provide a cover shown as layer 210 (e.g. decorative layer)configured with holes H (e.g. provided in a pattern, size and shape)with a substrate/backing 220 and with a translucent/transparent element(formed from resin R) shown as a light guide 230 with projectionsconfigured to fit into the holes H to present an image IM (e.g. byguided illumination from a light source) at the surface of the component1000.

According to an exemplary embodiment as shown schematically in FIGS. 22Ato 22C, a method of manufacturing a vehicle trim component 1000 maycomprise the steps of providing a decorative layer; disposing thedecorative layer in a tool; at least one of forming; cutting thedecorative layer into a shape; forming at least one hole in thedecorative layer; disposing the decorative layer in a mold; injecting aresin in the mold to form a light guide in the at least one hole of thedecorative layer; providing a base; joining the decorative layer withthe light guide to the base. The light guide may be configured to allowillumination to pass through the at least one hole of the decorativelayer. Forming the at least one hole may comprise perforating thedecorative layer with a laser. The method may comprise the step ofapplying a substrate shown as a backing (or backer) to an inner surfaceof the decorative layer. The backing/backer may comprise a barrierconfigured to prevent transmission of light. Forming at least one holein the decorative layer may comprise forming at least one hole in thebacking/backer to allow transmission of light through the at least onehole in the backing/backer.

According to an exemplary embodiment as shown schematically in FIG. 5B,component 1000 may be configured for an illuminated state to provideillumination shown as an image IM from a light source with the lightsource on Image IM may be formed by a pattern of illuminated/backlitholes H configured to provide indicia identifying or associated with atleast one vehicle system (e.g. instrumentation, control, etc.). Holes Hmay be filled with light guide 230 to improve visibility of image IM, inparticular visibility of image IM when viewed at smaller angles relativeto the visible surface of component 1000. Light guide 230 may protrudeinto holes H to provide visibility of image IM from a wider viewingangle than would be provided without light guide 230. Light guide 230may be configured to improve the brightness of image IM as compared tothe brightness of image IM in the absence of light guide 230. Lightguide 230 may be formed from a clear polycarbonate to optimize image IMcolor and impact strength of component 1000. Light guide 230 may beformed from a clear acrylic. Light guide 230 may comprise at least oneintegrally molded fastener for coupling light guide 230 to base 100.

According to an exemplary embodiment as shown schematically in FIG. 5A,component 1000 may be configured for a non-illuminated state with thelight source off. As shown schematically in FIG. 5A, when the lightsource is off, image IM may not be visible. The pattern of holes H maybe configured to provide a dead front or minimally visible image IM whennot backlit; holes H may be provided in an arrangement (e.g., pattern,form, shape, size, diameter, effective diameter, dimension/dimensions,profile, etc.) configured to provide an intended visual effect (e.g.optical effect, form/shape, intensity, contrast, etc.). A diameter DM ofholes H may be minimized to reduce visibility of the pattern of holes Hand image IM when not backlit. Diameter DM of holes H may be specifiedbased on a material of decorative layer 210 (for example a particularspecies of wood), a thickness of decorative layer 210 (for example,thinner decorative layers enable easier forming of smaller diameterholes H), the equipment used to form holes H in decorative layer (forexample the capability of a laser to form smaller diameter holes H indecorative layer 210) and control systems/software used to control theforming of holes H. Decorative layer 210 may comprise a thicknessgenerally between 0.005 inches and 0.05 inches to enable forming ofdecorative layer 210 into a contoured shape and/or enable forming ofholes H in decorative layer 210 of diameter less than 0.5 mm Holes H ofthe pattern of holes may be arranged (e.g. spaced closely together,separated, staggered, oriented, etc.) to provide improved quality ofimage IM (e.g. resolution, contrast, intensity, etc.). As shownschematically in FIG. 14B, a distance Y1/X1 between holes may beselected to provide minimum structural properties (such as strong orrigidity) and prevent component 1000 from being too brittle. Forexample, a 0.35 mm hole H diameter DM may be specified to provide a deadfront appearance when not backlit; a corresponding hole spacing may bekept at a minimum of 0.45 mm center to center, or a distance Y1/X1 mayspecified as 0.1 mm Holes H of the pattern of holes may be nested oraligned in rows and/or columns as shown schematically in FIG. 14A.Backing (e.g. barrier, backer, etc.) 220 may be applied or adhered todecorative layer 210 to provide rigidity to decorative layer. Backing(e.g. barrier, backer, etc.) 220 may comprise an opaque light barrier tomask/prevent visibility of portions of component 1000 when backlit.First backing/backer 220 a may be configured to reinforce decorativelayer during handling and/or forming. Second backing/backer 220 b may beconfigured to comprise an opaque light barrier to mask/preventvisibility of portions of component 1000 when backlit.

According to an exemplary embodiment as shown schematically in FIGS. 5Cand 5D, component 1000 may comprise a door panel comprising a base 100and a decorative insert 200. Decorative insert 200 may comprise adecorative layer 210, a backing (e.g. barrier, backer, etc.) 220 and alight guide 230. Component 1000 may comprise an armrest 300, an insert400 and a map pocket insert 500.

According to an exemplary embodiment as shown schematically in FIG. 8A,a conventional vehicle interior component 2200 may comprise a decorativelayer 2210 comprising at least one hole H and a base layer or circuitboard/module L/600 comprising a light source (e.g. comprising a lightemitting diode LED arrangement). Conventional vehicle interior componentP/2200 may comprise an air gap AG between decorative layer T/2210 and abase layer 600 and in the at least one hole of decorative layer 2210.

According to an exemplary embodiment as shown schematically in FIG. 22A,a method of manufacturing a vehicle trim component 1000 may comprise thesteps of providing a decorative outer layer, applying a backing (e.g.barrier, backer, etc.) to a back side of the outer layer, disposing theouter layer and the backing/backer in a hot tool, forming and cuttingthe outer layer and the backing/backer into a shape, cooling the outerlayer and the backing/backer in a fixture, perforating the outer layerand the backing/backer to form holes in the backing/backer and the outerlayer, disposing the perforated outer layer and the backing/backer in aninjection mold, injecting transparent polymer in the injection mold toform a light guide layer on the backing/backer and in the holes of thebacking/backer and the outer layer, providing a substrate with a lightsource and joining the light guide layer, the backing/backer and theouter layer to the substrate with the light source.

According to an exemplary embodiment as shown schematically in FIG. 22B,a method of manufacturing a vehicle trim component 1000 may comprise thesteps of providing wood veneer, applying light barrier to a back side ofwood veneer, disposing wood veneer with light barrier in a hot tool,forming wood veneer with light barrier into a shape, cooling wood veneerwith light barrier in a fixture, laser cutting wood veneer with lightbarrier to form holes in wood veneer and light barrier, disposing woodveneer with light barrier in injection mold, injecting transparentpolymer in injection mold to form light guide layer on light barrier andin holes, providing substrate with light source and joining light guidelayer, light barrier and wood veneer to substrate with light source.

According to an exemplary embodiment as shown schematically in FIG. 22C,a method of manufacturing a vehicle trim component 1000 may comprise thesteps of providing decorative outer layer, disposing outer layer in ahot tool, forming and cutting outer layer into a shape, cooling outerlayer in a fixture, perforating outer layer to form holes in outerlayer, disposing perforated outer layer in injection mold, injectingtransparent polymer in injection mold to form light guide layer on aback surface of outer layer and in holes of outer layer, providingsubstrate with light source and joining light guide layer and outerlayer to substrate with light source.

Referring to FIG. 23, a method/process for producing the componentconfigured with the display is shown schematically according to anexemplary embodiment to comprise the steps of applying a backer (e.g.backing arrangement of layer and/or layers) to an outer layer (e.g.cover or cover layer) and forming (e.g. in hot tool/mold) into the shapeand then perforating the cover/backer with holes (e.g. pattern forillumination to present image) and then injecting a light-transmissiveresin/polymer (e.g. transparent, translucent, etc.) to fill the holesand to provide a light guide arrangement and providing asubstrate/structure for the component (e.g. base, substructure, etc.)and assembly to the module (e.g. providing control/computing, lightsource, etc.). See also FIGS. 6, 6A-6D, 7, 8A-10A-10F, 16, 17, 18A-18C,19A-19C and 22A-22C.

It is important to note that the present inventions (e.g. inventiveconcepts, etc.) have been described in the specification and/orillustrated in the FIGURES of the present patent document according toexemplary embodiments; the embodiments of the present inventions arepresented by way of example only and are not intended as a limitation onthe scope of the present inventions. The construction and/or arrangementof the elements of the inventive concepts embodied in the presentinventions as described in the specification and/or illustrated in theFIGURES is illustrative only. Although exemplary embodiments of thepresent inventions have been described in detail in the present patentdocument, a person of ordinary skill in the art will readily appreciatethat equivalents, modifications, variations, etc. of the subject matterof the exemplary embodiments and alternative embodiments are possibleand contemplated as being within the scope of the present inventions;all such subject matter (e.g. modifications, variations, embodiments,combinations, equivalents, etc.) is intended to be included within thescope of the present inventions. It should also be noted thatvarious/other modifications, variations, substitutions, equivalents,changes, omissions, etc. may be made in the configuration and/orarrangement of the exemplary embodiments (e.g. in concept, design,structure, apparatus, form, assembly, construction, means, function,system, process/method, steps, sequence of process/method steps,operation, operating conditions, performance, materials, composition,combination, etc.) without departing from the scope of the presentinventions; all such subject matter (e.g. modifications, variations,embodiments, combinations, equivalents, etc.) is intended to be includedwithin the scope of the present inventions. The scope of the presentinventions is not intended to be limited to the subject matter (e.g.details, structure, functions, materials, acts, steps, sequence, system,result, etc.) described in the specification and/or illustrated in theFIGURES of the present patent document. It is contemplated that theclaims of the present patent document will be construed properly tocover the complete scope of the subject matter of the present inventions(e.g. including any and all such modifications, variations, embodiments,combinations, equivalents, etc.); it is to be understood that theterminology used in the present patent document is for the purpose ofproviding a description of the subject matter of the exemplaryembodiments rather than as a limitation on the scope of the presentinventions.

It is also important to note that according to exemplary embodiments thepresent inventions may comprise conventional technology (e.g. asimplemented and/or integrated in exemplary embodiments, modifications,variations, combinations, equivalents, etc.) or may comprise any otherapplicable technology (present and/or future) with suitability and/orcapability to perform the functions and processes/operations describedin the specification and/or illustrated in the FIGURES. All suchtechnology (e.g. as implemented in embodiments, modifications,variations, combinations, equivalents, etc.) is considered to be withinthe scope of the present inventions of the present patent document.

1. A component for a vehicle interior with an interface at a surfaceintended to be visible to an occupant when the component is installed inthe vehicle interior configured to provide illumination from a lightsource comprising: a base; a decorative layer coupled to the basecomprising at least one hole; and a light guide coupled to thedecorative layer; wherein the light guide comprises a first portionconfigured to fill the at least one hole in the decorative layer;wherein the light guide comprises a light-transmissive resin materialformed in the at least one hole of the decorative layer; wherein the atleast one hole comprises a pattern of holes; wherein the base comprisesa sensor; wherein the pattern of holes is configured to illuminate thedecorative layer to indicate a position of the interface.
 2. Thecomponent of claim 1 further comprising a backing coupled to a rearsurface of the decorative layer.
 3. The component of claim 1 wherein theat least one hole comprises a pattern of holes configured to provideindicia identifying at least one vehicle control.
 4. The component ofclaim 1 wherein the decorative layer comprises a backer configured toprevent illumination to pass from a light source to an outer surface ofthe decorative layer.
 5. The component of claim 1 wherein the lightguide is formed within the at least one hole of the decorative layer. 6.The component of claim 1 wherein the decorative layer is configured toprovide a visual effect; wherein the light guide is configured toprovide a visual effect; and wherein the visual effect of the decorativelayer and the visual effect of the light guide are configured to providea composite visual effect
 7. A component for a vehicle interior producedby a method of manufacturing comprising the steps of: (a) providing adecorative layer; (b) providing the decorative layer in a tool; (c) atleast one of forming; cutting the decorative layer into a shape; (d)forming at least one hole in the decorative layer; (e) providing thedecorative layer in a mold; (f) injecting a resin in the mold to form alight guide in the at least one hole of the decorative layer; (g)providing a base; (h) joining the decorative layer with the light guideto the base; wherein the light guide comprises a light-transmissiveresin material; wherein the at least one hole comprises a pattern ofholes configured to provide indicia.
 8. The method of claim 7 whereinthe light guide is configured to allow illumination to pass through theat least one hole of the decorative layer.
 9. The method of claim 7wherein forming the at least one hole comprises perforating thedecorative layer with a laser.
 10. The method of claim 7 furthercomprising the step of applying a backer to an inner surface of thedecorative layer.
 11. The method of claim 10 wherein the step of formingat least one hole in the decorative layer comprises forming at least onehole in the backer to allow transmission of light through the at leastone hole in the backer.
 12. A component for a vehicle interiorcomprising a surface configured to be illuminated by a light source topresent an interface for an occupant of the vehicle interior comprising:(a) a base; (b) a cover layer coupled to the base comprising a patternof apertures; and (c) a light guide coupled to the cover layer; whereinthe light guide comprises a set of projections configured to fit in thepattern of apertures of the cover layer; wherein the light guide isconfigured to transmit illumination from the light source to present theinterface through the pattern of apertures of the cover layer; whereinthe light guide comprises a light-transmissive resin material formed inthe pattern of apertures of the cover layer; wherein the pattern ofapertures is configured to illuminate the cover layer to indicate aposition of the interface.
 13. The component of claim 12 wherein thecover layer comprises a decorative layer for the surface; wherein thedecorative layer comprises at least one of (a) a natural material; (b) awood veneer; (c) a grained material; (d) a sheet material providing asurface effect.
 14. The component of claim 12 wherein the pattern ofapertures comprises at least one hole configured to at least one of (a)provide an outlet for light configured to provide illumination; (b)direct light to provide illumination.
 15. The component of claim 12wherein the pattern of apertures is configured to provide a display. 16.The component of claim 12 further comprising a module configured toprovide the light source and at least one sensor for the interface. 17.The component of claim 12 further comprising a backer configured toreinforce the cover layer.
 18. The component of claim 17 wherein thebacker is configured to prevent illumination from the light source to anouter surface of the decorative layer other than at the pattern ofapertures.
 19. The component of claim 17 wherein the light guidecomprises a resin material formed as the set of projections in thepattern of apertures.
 20. The component of claim 17 wherein the coverlayer comprises a decorative layer configured to provide a visualeffect; wherein the light guide is configured to provide a visualeffect; and wherein the visual effect of the decorative layer and thevisual effect of the light guide are configured to provide a compositevisual effect.